Method of vibrating coatings while drying so as to impart a pattern thereto



429 919 SR pms-q Xi? 2.544.682

1 March 6, 1951 w. w. ULMER ET AL 2,544,622 .I METHOD OF VIBRATING COATINGS WHILE DRYING l 50 AS TO IMPART A PATTERN THERETO Filed Jan. 30, 1948 i Mum/v Wan/2 4w 1 JNVENTOR.

y w c; 9 BY WNW Z0 v 4/ flTTOE/VEYJ.

Pate nted Mar. 6, 1951 T METHOD OF VIBRATING COATINGS WHILE DRYING SO AS TO IMPART A PATTERN THERETO William Walter Ulmer, Alexandria, and Louis R. Burroughs, South Bend, Indt; said Burroughs assignor to said 'Ulmer Application January 30, 1948, Serial No. 5,288

" 5 Claims. (01.117-62) which there are a number of different types or grades, some differing as to properties, chemical composition and molecular weight, will be referred to herein as synthetic resins. It will be understood, however, that there are many other synthetic resins than those specifically mentioned above. from which, by mixture with plasticizers and solvents therefor, and by dipping of be selectively provided therein during formation thereof and which impart thereto novel decorative and camoufiaging effects.

A further object isflto provide a novel method for controlling the thickness of a plastic film. A further object is to provide a novel method for introducing" a design in a plastic film.

A further! object is to provide a method of preparing ,a stable colloidal suspension of plastic, plasticizer and solvent from which a film having desired properties may be produced.

Other objects will be iapparent from the description, drawings and appended claims.

. In the drawings:

Figs; 1' to 3, inclusive, are face views of a fragment of a film having different characteristic de signs or patterns. filFig. '4 is a perspective view of a patterned Fig. 5 is a view of one form of apparatus for producing the plastic film.

Fig.'6 is a view of a diiierent film-forming apparatus.

Fig. 7 is a view of a third type of film-forming apparatus.

' Fig. 8 is a diagrammatic view of another type of film-forming apparatus.

This application is a continuation inpart of our co-pendiiig application, Serial No.556,462,

filed September 29, 1944, now abandoned.

, The plastic films to which this invention relates are very thin films possessing waterproof properties-and at least a limited degree of elasticity. They may be used for many purposes, some of which are bathing caps, moisture seals for electric instruments, diaphragms for low pressure measuring instruments, shower curtains, packaging or wrapping material, and the like. Preferably they are formed essentially of natural or synthetic materials, such as polyvinyl chloride, polyvinyl chloride-acetate copolymer, cellulose acetate andcellulose nitrate. Films of a form or spreading on a form, a film may be' produced, and therefore the invention will be understood to apply to them as well as the materials named specifically herein. Also the film may constitute a coating of synthetic resin applied to a base, such as a paper, cloth or fibrous sheet and adhered thereto, as by partial or complete impregnation of said sheet by the synthetic resin.

The properties of a film produced from a synthetic resin depend upon the individual character of the specific base material employed, upon The nature and proportion of a plasticizing material used therewith, and upon the nature and amount of the solvent used therewith. These materials must be so mixed that the resulting mixture is uniform throughout and is in the nature of a colloidal suspension. For best results the film-forming material should be stable, i. e., should not be subject to precipitation of solids. Any departure from a uniform stable condition of the film-forming material will result in the production of films therefrom which lack uniformity of thickness and other characteristics and properties desired.

We have discovered that a stable film-forming material can be produced by mixing the synthetic resin, plasticizer and solvent in desired proportions, and cooking the mixture at a temperature just under the boiling point of the solvent for an extended period of time during which the mixture is continuously stirred. One example is to mix 32 gms. of polyvinyl chloride-ace tate copolymer in the grades of heaviest molecular weight with 20 gms. of a plasticizer such as synthetic rubber formed by dipping, and films of dioctyl phthalate or tricresyl phosphate, and with two pounds of a solvent such as methyl ethyl ketone. If such a mixture is cooked at a temperature of from F. to F. for 1 /2 hours with continuous st rring, a stable colloidal dispersion of the resin and the plasticizer' in the solvent is obtained. The film-forming mixture so prepared will stand for long periods of time without noticeable precipitation. Also, stirring of this mixture during the operation of forming a film is substantially or practically avoided. It will be understood, however, that the above prep- .lUNl'l ED STATES PATENT E aration and treatment is illustrative, and that the treatment used will vary with the co'mposie tion and character of the synthetic resin and of the particular plasticizing material and solvent used.

There is a substantial range of the proportions in which the constituent materials may be mixed. The proportions given above are intended for theproduction of a very thin film. However, the pro-- portions may be varied by either reducing or increasing the amount of the resin employed, re-

duc'ed amounts of resin used resulting in thinner films and use of increased amounts thereof producing a thicker film.

The film may be made with apparatus of the type illustrated in Fig. 5. A container 20 open at its upper end contains a quantity or bath 2| of "the synthetic resin film-forming liquid described above or any other liquid material from which a film of the typev mentioned above may be formed. A frame 22 extends above the top of container 20 and journals a pulley 23. A plate 24, preferably formed of glass or other material having a very smooth surface, may be supported in vertical position by a bracket: or clamp suspended from a cable 26 or the like trained around a pulley 23. Suitable means, h'ere illustrated as a drum 2! journalled in a bracket 28 and operated by a crank are provided to play out and pull upon the cable to lower the plate 24 into the bath and withdraw it from the bath. It may be critical to both uniformity of the film produced and the thickness thereof.

Thus, if a mixture, preparedin the manner and of the proportions described above is withdrawn very slowly, at a rate not faster than the rate at which the mixture will flow, for example at a rate of about 4 /2 inches per minute, a film of minimum thickness, i. e. injfthe order pf a thickness of .0004 inch yvill be "produced upon the surface of the plate 24. Withdrawal of plate 24 from the same solution at a faster rate will produce a thicker film 30 upon plate 24, for example, withdrawal ata rate of about 36 inches per minute producing "I a film in the order of .0012 thickness. For any givemmixture therewill be a minimum and a maximum film thickness obtainable. Thicknesses between these limits can be obtained by'proper ,timing of the rate of withdrawal. Therefore, two factors control film thickness, i. e., the consistency of the bath and the rate of form withdrawal. Hence it is possible to produce a film of any of a wide range of thicknesses and a wide range of properties, such as elongation, resilience and the like. The film can be stripped from the form easily, since it has only a frictional adhesion therewith, and its elasticity and fiexibilty assists in the operation of peeling it from the form. The thinness of the film facilitates the drying action.

The temperature at which the bath is maintained is not critical with the polyvinyl chlorideacetate'copolymer mentioned above, and satisfactory results can be obtained, without detrimental effect upon the properties of the bath, if the same is maintained at any temperature which is below the boiling point of the solvent and above the solidifying point of the mixture. Thus the operation can be conducted to produce a satisfactory filmat a temperature as low as 20 C. and as high as 79 C., with the mixture described above. Temperatures in the upper part of this range are naturally preferred. The temperature employed with other of the synthetic resinimaterials will depend upon the properties thereof and of the plasticizer and solvents used therewith,

as is well understood in the art.

The film produced by the above method will I be of uniform thickness and clear and transparent, if the constituent materials are not pigmented. Colors can be incorporated asdesired;

use of a scraper, after which the film is permitted to set and dry. The latter method may be practiced by either of the types of apparatus shown in Figs. 6 and 7, wherein the horizontal forming plate-is illustrated at 35, and also may be practiced by forming a film on a web or belt in a 5 continuous,process, as shown in Fig. 8. The advantage of these methods lies principally in their adaptation to the provision of design patterns in the film being formed. Thus, referring to Fig. 6, the plate 35 is mounted on a suitable horizontal support 36 in which is journaled a shaft 31 driven by an electric motor 38. Cams 3 u1may be mounted on shaft 31 of such a size and shape that they engage and vibrate the plate 35 at a predetermined or selected period. While one shaft 31 mounting two cams 39 has been illustrated, it will be understood that a plurality of cams shafts may be employed, operating at the same or different speeds depending on the design pattern desired, that each shaft may mount one or'any selected number of cams, and that the cams may be of the same contour or different contours depending upon the design pattern desired. In the apparatus shown in Fig. '7, the plate 35 rests upon support 36 and is engaged by the spring pressed armatures 40 of solenoids ated.

In the apparatus shown in Fig. 8, an endless web or belt 60 of any suitable material is trained around rollers 6|, one of which is preferably power driven. The upper run of the belt has the fluid synthetic resin applied thereto at 62,- as by flowing the same thereon from a container 63. The resin coating is smoothed and its thickness regulated by suitable means such as rollers 64. Thereafter the belt is acted upon by one or more vibrators 65 while it is solidifying and setting.

The completed film B6 is separated from the be1t,'as byf-scraper 61, after it has dried or set means, certain properties of the film result.

The film assumes 'a definite patterned or design appearance as the result of the vibration. Characteristic design patterns are illustrated in Figs. 1, 2, 3, and 4. It will be understood, of course, that the'designs illustrated in said Figs. 1 to 4 are illustrative only and not limiting, since the number of designs and the character thereof is almost infinite. There is, for example, a'definite relation between the nature of the design pattern and the amplitude and period of vibration. Also, the, mixture employed in the filmforming bath determines design characteristics. .Where pigmented materials are employed, the design is quite pronounced, and is characterized by areas of darker and lighter shades of the same color. In' exceedinglyy'thin films or any film which is translucent and normally transparent, these properties are retained in the designed or patterned film, but the design breaks the continuity of an image viewed therethrough by an effect upon the eye which can be likened to that of camoufiaging.

rative and other uses.- The Vibration preferably occurs as the film is being dried, and in most cases entails a certain degree of thickening of the film at the pattern-forming lines r areas. This is not noticeable in thin films which have been vibrated at high frequency, but increases as film thickness and amplitude of vibration increase and as the frequency of vibration decreases. i

The-process of forming a design upon syntheticmesin film is not limited to performance at the time when the film is being formed. Thus a preformed film may be treated to impart a design thereto. Such treatment entails softening at least the surface portion of the preformed film to render the same fully or partially fluid, as by applying a solvent thereto or by the combincd action of heat and a solvent. When the film or film surface has been softened or rendered fluid to a degree to permit it to be reworked or reshaped, it can be subjected to vibrationby any suitable means during the time the shaped.

solvent is evaporating and the film is setting to self-sustaining condition, 1. e. until its shape or form can no longer be varied or until it will retain its shape or contour unless forcibly 1e- In this connection, films of the type jlznown in the art as dipped films orpast or molded films can be readily worked by this contains some of the solvent and possesses at least a measure of free fluidity and must continue until enough of the solvent is evaporated so that such fluidity; ceases and the film becomes These properties,

v I v, 2,544,022

self-sustaining or shape-retaining, and preferably until it is no longer workable or until it can only be worked by application of substantial forming pressure thereto.

Vibration within a wide range of frequencies .limit of approximately 200 cycles per second to a high limit of approximately 30,000 cycles per second. The pattern produced varies with the frequency, and Fig. 3 is illustrative ofa coarse pattern produced at low frequencies; Fig. 2 is illustrative of a fine pattern produced at high frequencies; and Fig. 1 is comparatively illustrative of a pattern produced at an intermediate frequency. The pattern will vary somewhat with the thickness of the film, particularly where the amplitude of vibration at a given frequency remains constant when applied to films of the same material but of different thickness. In general, however, if amplitude of vibration is increased proportionally to increases in film thickness, the change of design for a given frequency upon films of the same material but of different thicknesses will be small. The thickness of the film may vary from approximately .002 inch to approximately .012 inch. Films of thicknesses greater than the latter limit do not offer? a satisfactory basis for the practice of the method under all conditions, although they are not completely devoid of properties permitting practice of the method. Also, films at or near the upper limit of thickness generally are less susceptible of designing at frequencies at or near the upper end of the frequency range specified than thinner films. The greatest variation of design pattern occurs at the lower frequencies; thus at frequencies of vibration exceeding 16,000 cycles per second, very large differences yin frequency are required to produce substantial or appreciable differences in design.

Such material may be vibrated in any manner suitable, and in cases where the coatin thickness is within the range specified and the vibration applied is within the range specified and is of suificient amplitude and duration, the production of a design will result.

The vibrated film, in addition to its design, will also be characterized by a rippled surface at the face thereof opposite that which bears against the form or support, or at the coating surface or coated sheet material. This can readilybe detected in the coarse patterns, especially where the amplitude of vibration has been substantial, and becomes less noticeable as the pattern becomes finer. Such ripples obviously entail the formation of surface ridges and depressions, and therefore the thickness of the film varies from point to point, although the differences will usually be very small and will not appreciably reduce the strength of the film or be otherwise detrimental.

Synthetic resins of the types described above may be plasticized by other materials than those mentioned above. The proportions in which such other plasticizers are used will depend upon the synthetic resins with which they are used,

The range of frequencies efas is well understood in the art, and different plasticizers may be found to be preferable to secure different characteristics which it is desired to obtain in films made for different specific uses, and purposes.

Different solvents from that specifically mentioned above may also be used. The proportions in which different solvents are incorporated will d pend essentially upon the molecular weight o r specific gravity of each. solvent and on the synthetic resin and plasticizer with which each is used. In general, as

the specific gravity of solvents increases, an inl compatible with the synthetic resins. Tests made synthetic rubber, said film containing a solvent for said film-forming material, and vibrating said support and film at a frequency in the range from 200 to 30,000 cycles per second until the solvent has been evaporated and the film solidified.

2. The method of making a film of an organic film-forming plastic material which comprises applying to the surface of a support a thin uniform fluid coating of a colloidal dispersion of an adding to polyvinyl chloride-acetate copolymer a different synthetic resin, such as methyl methacrylate, and to synthetic rubber materials as Buna S and Hycar" show that they'are lcomp'atible.

The materials listedwill be understood to be illustrative and not t o be complete. The properties of the film differ according to such other materials added to and forming part of the film forming bath, among which may be i. mentioned dryiri g characteristics and different degrees of elasticity. Hence, for a given use,

where certain properties are essential, the filmforming bath may be formulated by variation of the illustrative formula given above to provide such properties in the film. Also, it has been found that the design patterns resulting from vibration differ with the different synthetics incorporated in the film-forming liquid. In other words, a material containing methyl methacrylate and polyvinyl chloride-acetate copolymer, when processed: to a given film thickness and vibratedat a lgiven frequency will have' a different desigm pattern than a material 3 the volatile ,l:;onstituents, of the film-forming material have'been evaporated or. expelled. The

1. film is subject to shrinkage and has an odor characteristic of the solvents, until it becomes In the thin sections of the order to i stable.

in most cases.

, Weclaim: p l. The method of depositing a thin layer of an organic film-forming plastic material which which reference has been made, complete dryhing; can be accomplished by simply exposing it to atmosphere.

However, complete elimination or evaporation of volatile constituents by air drying is slow" Th'erefore, it is preferable fOli practical considerations to pass the film through a heated chamber or otherwise subject it. to heat to accelerate expulsion of volatile constituents comprises applying to a support a thin fluid film of an organic film-forming material selected from the group consisting of vinyl resins and organic film-forming material selected from the group consisting of vinyl resins and synthetic rubber, said colloidal dispersion containing a solvent for said film-forming material, and

vibrating said support and film at a frequency between 200 and 30,000 cycles per'second until the solvent has been evaporated and the colloidal dispersion solidified.

3. That step in the method of producing a' thin layer of an organic film-forming plastic material having at one surface thereof an undulant contour imparting a design pattern to a surface of said film which comprises supporting upon a base a thin fluid film of an organic filmforming material selected from the group consisting of vinyl resins and synthetic rubber, said film containing a solvent for said film-forming material, and vibrating said base and film at a frequency between 200 and 30,000 cycles per second until the solvent has been evaporated and the film solidified, said undulant surface 3 being formed at the surface of the film opposite that which contacts the base.

4. The method of making a thin flexible film fibrous sheet which comprises applying to said I sheet, to at least partially saturate said sheet, a thin film of an organic film-forming material selected from the group consisting of vinyl resins and synthetic rubber, said film containing a solvent for said film-forming material,

and

vibrating said fibrous sheet and said film at a frequency in the range between 200 and 30,000 cycles per second until the solvent has been evaporated and the film solidified.

WILLIAM WALTER ULMER.

LOUIS R. BURROUGHS.

' REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Q 65 Number Name Date 2,080,494 Martindell v May 18, 1937 2,238,730 Hauffe Apr. 15, 1941 2,259,352 Osterhof Oct. 14, 1941 2,325,126 Giesler July 27, 1943 g lt/n- 

1. THE METHOD OF DEPOSITING A THIN LAYER OF AN ORGANIC FILM-FORMING PLASTIC MATERIAL WHICH COMPRISES APPLYING TO A SUPPORT A THIN FLUID FILM OF AN ORGANIC FILM-FORMING MATERIAL SELECTED FROM THE GROUP CONSISTING OF VINYL RESINS AND SYNTHETIC RUBBER, SAID FILM CONTAINING A SOLVENT FOR SAID FILM-FORMING MATERIAL, AND VIBRATING SAID SUPPORT AND FILM AT A FREQUENCY IN THE RANGE FROM 200 TO 30,000 CYCLES PER SECOND UNTIL THE SOLVENT HAS BEEN EVAPORATED AND THE FILM SOLIDIFIED. 